Fuel Injector: Service and Repair

SPECIAL TOOLS






Removal

1. Remove the air cleaner assembly and resonator.
2. Drain the fuel from the cylinder heads.

^ Loosen the drain plugs, located at the rear of each cylinder head.










3. If removing injector 3 or 5, carry out the following:

1 Disconnect the A/C compressor clutch wire.
2 Raise the vehicle.
3 Loosen the right hand motor mount nuts.
4 Remove the LH engine mount-to-engine bolts.
5 Raise the engine.
6 Remove the LH engine mount-to-crossmember nuts.
7 Remove the LH engine mount.
8 Lower the engine until the oil pan is resting on the crossmember.

4. Remove the valve cover.
5. Remove the fuel charging wiring.
6. Remove the oil drain plugs.






7. NOTE: Rocker arm removed for clarity. Rocker arm removal is not required for fuel injector removal and installation.

Remove the bolt and the oil deflector from the fuel injector hold-down plate.






8. NOTE: The inboard fuel injector hold-down bolts do not require removal to remove the fuel injectors.

Remove the outboard fuel injector hold-down bolts.






9. NOTE: When removing the fuel injectors, it is important that the injector tip copper washer is removed from the injector bore. If the copper washer is not on the injector when removed from the cylinder head, make sure to remove it from the injector bore.

Using the special tool, remove the fuel injector.






10. Place the fuel injector into the special tools.






11. NOTE: If engine coolant is found in the combustion chambers then new injector sleeves may need to be installed.

NOTE: To install new fuel injector sleeves, the cylinder heads must be removed from the vehicle.

Remove the cylinder heads.

12. NOTE: Place a plastic cap or a small piece of cork, to act as a stop, in the injector sleeve before installing special tool 303-D107 (D94T-9000-B2). This will prevent damage to the cylinder head bore.

Insert special tool 303-D106 (D94T-9000-B1) and special tool 303-D107 (D94T-9000-B2) into the cylinder head fuel injector bore. Tighten special tool 303-D106 (D94T-9000-B1) 1-1/2 to 2 turns. Attach special tool 100-001 (T50T-100-A) to special tool 303-D106 (D94T-9000-B1), and remove the fuel injector sleeve from the cylinder head fuel injector bore. Discard the sleeve.






13. Using the special tool, remove sealant residue and all foreign material from the cylinder head fuel injector bore.






INSTALLATION

1. Position the fuel injector sleeve onto the special tool. Apply Threadlock 620 or equivalent to the fuel injector sleeve.






2. Position the fuel injector sleeve into the cylinder head fuel injector bore. Using a rubber mallet, seat the fuel injector sleeve in the fuel injector bore. Remove the special tool from the cylinder head fuel injector bore.






3. Using the special tool, clean the fuel injector sleeve and bore. Remove any sealant residue from the fuel injector bore.






4. Install new 0-rings on the fuel injector. Lubricate the fuel injector and 0-rings liberally with clean engine oil.

5. If required, install the cylinder heads.

6. CAUTION: Remove all oil and fuel from the cylinders before installing the fuel injectors. Failure to do so can cause hydrostatic lock, resulting in severe engine damage.

CAUTION: Do not strike the top of the fuel injector to seat the injector in the cylinder head fuel injector bore. Damage to the fuel injector will occur. Use hand pressure on the top of the fuel injector until the fuel injector hold-down plate is flush with the cylinder head.

Install the fuel injector.

1 Insert the fuel injector into the cylinder head fuel injector bore.
2 Using the injector replacer, seat the fuel injector into the cylinder head fuel injector bore.






7. Install the outboard fuel injector hold-down bolts.






8. Install the oil deflector on the fuel injector hold-down plate, using the shoulder bolt.






9. Install the oil drain plugs.






10. Tighten the fuel drain plug located at the rear of each cylinder head.






11. Position the valve cover gasket onto the cylinder head.
12. Install the fuel charging wiring.
13. Install the valve covers.
14. Connect the A/C compressor wire.
15. Install the left motor mount and tighten the right motor mount nuts.
16. Install the resonator and air cleaner assembly.